Method and apparatus for filling containers

ABSTRACT

A filling apparatus for, a filling system for and a method of introducing into a container a suspension or solution of a substance, in particular a pharmaceutical substance, in a propellant under pressure, the filling apparatus comprising: a main body ( 4 ) including a passageway ( 20 ) having an inlet opening ( 21 ) and first and second outlet openings ( 25, 22 ), the first outlet opening ( 25 ) communicating, in use, with a valve stem ( 144 ) extending from a head ( 141 ) of a body ( 139 ) of a container ( 138 ); a fill actuator ( 7 ) in communication with the inlet opening ( 21 ) of the passageway ( 20 ) comprising a filling valve assembly ( 29 ) for selectively introducing propellant under pressure containing a substance in a suspension or solution into the passageway ( 20 ); an exhaust actuator ( 10 ) in communication with the second outlet opening ( 22 ) of the passageway ( 20 ) comprising an exhaust valve assembly ( 48 ) for selectively exhausting propellant under pressure containing substance from the passageway ( 20 ) and including at least one exhaust gas conduit ( 84, 92, 93 ) having an outlet ( 86, 94, 95 ) configured so as, in use, to provide a flow of exhaust gas substantially aligned with a flow of propellant containing substance from the second outlet opening ( 22 ) of the passageway ( 20 ); and a container-engaging body ( 16 ) for receiving, in use, the head ( 141 ) of the body ( 139 ) of the container ( 138 ) which includes the valve stem ( 144 ).

[0001] The present invention relates to a filling apparatus for, afilling system for and a method of introducing into a container asuspension or solution of a substance, in particular a pharmaceuticalsubstance, in a propellant under pressure. Most particularly, thepresent invention relates to a filling head included in a line in whicha propellant under pressure containing a substance in a suspension orsolution is circulated, with the filling head being brought into and outof communication with containers to be filled.

[0002] Containers for holding a suspension or solution of apharmaceutical substance in a propellant under pressure are well known.One such known container comprises a body which defines a storagechamber, a valve stem which extends from a head of the body and ametering chamber which is selectively communicatable by the valve stemwith the atmosphere and the storage chamber; the valve stem providing,via an L-shaped conduit which extends between the free end and the sidewall thereof, the outlet of the container through which metered doses ofpropellant containing pharmaceutical substance are delivered. The valvestem is axially displaceable between a first, extended position in whichthe metering chamber, and hence the container, is closed to theatmosphere since the L-shaped conduit is disposed wholly outside themetering chamber, and a second, depressed position, in which themetering chamber is in communication with the outlet provided by theL-shaped conduit in the valve stem and through which a metered dose ofpropellant containing pharmaceutical substance is delivered. Thecontainer is filled with the valve stem in the depressed position, withthe propellant containing pharmaceutical substance being forceddownwardly through the L-shaped conduit in the valve stem, through themetering chamber and into the storage chamber defined by the body of thecontainer.

[0003] EP-A-0419261 discloses a filling system for introducing into acontainer a suspension or solution of a pharmaceutical substance in apropellant under pressure, which filling system includes a fillingapparatus that prevents the escape of pharmaceutical substance into theatmosphere. In this filling system the filling apparatus is configuredto be flushed by a volume of high pressure propellant while still influid communication with the container so that the propellant underpressure containing pharmaceutical substance which is remaining in thefilling apparatus after filling the container with the same is flushedthrough into the container prior to withdrawal of the filling apparatusfrom the container. This configuration does, however, require additionalpropellant to be introduced into the container to achieve the flush.Moreover, following the flushing action, propellant under pressurepresent in the valve stem can escape to the atmosphere.

[0004] The present invention in at least one preferred aspect aims toprovide an improved filling apparatus which at least partially overcomesthe above-mentioned problems.

[0005] The present invention also aims to provide a method and fillingsystem which are configured to fill a container without requiring therelease of propellant alone or propellant containing pharmaceuticalsubstance directly to the atmosphere.

[0006] The present invention provides a filling apparatus forintroducing into a container a suspension or solution of a substance, inparticular a pharmaceutical substance, in a propellant under pressure,comprising: a main body including a passageway having an inlet openingand first and second outlet openings, the first outlet openingcommunicating, in use, with a valve stem extending from a head of a bodyof a container; a fill actuator in communication with the inlet openingof the passageway comprising a filling valve assembly for selectivelyintroducing propellant under pressure containing a substance in asuspension or solution into the passageway; an exhaust actuator incommunication with the second outlet opening of the passagewaycomprising an exhaust valve assembly for selectively exhaustingpropellant under pressure containing substance from the passageway andincluding at least one exhaust gas conduit having an outlet configuredso as, in use, to provide a flow of exhaust gas substantially alignedwith a flow of propellant containing substance from the second outletopening of the passageway; and a container-engaging body for receiving,in use, the head of the body of the container which includes the valvestem.

[0007] Preferably, the exhaust actuator includes a plurality of firstexhaust gas conduits, the respective outlet openings of which define anarray surrounding the second outlet opening of the passageway.

[0008] More preferably, the outlet openings of the first exhaust gasconduits are disposed downstream, with respect to the direction of flow,of the second outlet opening of the passageway.

[0009] More preferably, the array of outlet openings of the firstexhaust gas conduits define a circular array.

[0010] Preferably, the exhaust actuator includes a first chamber withwhich the first exhaust gas conduits commonly communicate and a conduitin communication with the first chamber through which exhaust gas isdelivered.

[0011] In a preferred embodiment the exhaust actuator includes aplurality of second exhaust gas conduits, the respective outlet openingsof which are downstream, with respect to the direction of flow, of theoutlet openings of the first exhaust gas conduits and define an arraysurrounding the second outlet opening of the passageway.

[0012] Preferably, the array of outlet openings of the second exhaustgas conduits define a circular array.

[0013] Preferably, the exhaust actuator includes a second chamber withwhich the second exhaust gas conduits commonly communicate and a conduitin communication with the second chamber through which exhaust gas isdelivered.

[0014] Preferably, the exhaust valve assembly includes an exhaust valvebody which is configured selectively to be seated on or unseated from avalve seat disposed at the second outlet opening of the passageway and asubstantially annular chamber which surrounds the exhaust valve bodythrough which, in use, flows propellant containing substance and exhaustgas when the exhaust valve body is unseated from the valve seat.

[0015] More preferably, the annular chamber is conical in shape,increasing in diameter from the second outlet opening of the passageway.

[0016] The present invention also extends to a filling system forintroducing into a container a suspension or solution of a substance, inparticular a pharmaceutical substance, in a propellant under pressureincorporating the above-described filling apparatus.

[0017] The present invention further provides a method of introducinginto a container a suspension or solution of a substance, in particulara pharmaceutical substance, in a propellant under pressure, comprisingthe steps of: providing a container comprising a body defining a storagechamber and a valve stem extending from the body; communicating thevalve stem of the container with a first outlet opening of a passagewayin a main body of a filling apparatus, the filling apparatus comprisinga fill actuator comprising a filling valve assembly for selectivelyintroducing into an inlet opening of the passageway propellant underpressure containing a substance in a suspension or solution and anexhaust actuator comprising an exhaust valve assembly for selectivelyexhausting propellant under pressure containing substance from a secondoutlet opening of the passageway and including at least one exhaust gasconduit having an outlet configured so as, in use, to provide a flow ofexhaust gas substantially aligned with a flow of propellant containingsubstance from the second outlet opening of the passageway; opening thefilling valve assembly thereby to fill the storage chamber of thecontainer with propellant under pressure containing substance in asuspension or solution; closing the filling valve assembly; providingexhaust gas through the at least one exhaust gas conduit; and openingthe exhaust valve assembly to enable propellant under pressurecontaining substance in the passageway and the valve stem of thecontainer to exhaust, whereby the exhausted propellant containingsubstance is entrained in the exhaust gas.

[0018] Preferably, the exhaust actuator includes a plurality of firstexhaust gas conduits, the respective outlet openings of which define anarray surrounding the second outlet opening of the passageway.

[0019] More preferably, the outlet openings of the first exhaust gasconduits are disposed downstream, with respect to the direction of flow,of the second outlet opening of the passageway.

[0020] More preferably, the array of outlet openings of the firstexhaust gas conduits define a circular array.

[0021] Preferably, the exhaust actuator includes a first chamber withwhich the first exhaust gas conduits commonly communicate and a conduitin communication with the first chamber through which exhaust gas isdelivered.

[0022] In a preferred embodiment the exhaust actuator includes aplurality of second exhaust gas conduits, the respective outlet openingsof which are downstream, with respect to the direction of flow, of theoutlet openings of the first exhaust gas conduits and define an arraysurrounding the second outlet opening of the passageway.

[0023] Preferably, the array of outlet openings of the second exhaustgas conduits define a circular array.

[0024] Preferably, the exhaust actuator includes a second chamber withwhich the second exhaust gas conduits commonly communicate and a conduitin communication with the second chamber through which exhaust gas isdelivered.

[0025] Preferably, the exhaust valve assembly includes an exhaust valvebody which is configured selectively to be seated on or unseated from avalve seat disposed at the second outlet opening of the passageway and asubstantially annular chamber which surrounds the exhaust valve bodythrough which, in use, flows propellant containing substance and exhaustgas when the exhaust valve body is unseated from the valve seat.

[0026] More preferably, the annular chamber is conical in shape,increasing in diameter from the second outlet opening of the passageway.

[0027] Preferably, the exhaust gas is heated to a temperature of atleast about 35° C.

[0028] Preferably, the ratio of the mass flow rate of the exhaust gas tothe exhausted propellant containing substance is at least 10:1.

[0029] Preferably, the exhaust gas has a mass flow rate of from 0.1 to10 grams/second.

[0030] Preferably, the exhaust gas comprises pressurised air.

[0031] A preferred embodiment of the present invention will now bedescribed hereinbelow by way of example only with reference to theaccompanying drawings, in which:

[0032]FIG. 1 illustrates a part-sectional side view of a filling head inaccordance with a preferred embodiment of the present invention;

[0033]FIG. 2 illustrates a vertical sectional view (along section A-A)of the filling head of FIG. 1;

[0034]FIG. 3 illustrates a horizontal sectional view (along section B-B)of the filling head of FIG. 1;

[0035]FIG. 4 illustrates an underneath plan view of the filling head ofFIG. 1;

[0036]FIG. 5 illustrates an end view of the filling head of FIG. 1,illustrated with part of the housing of the exhaust actuator removed;

[0037]FIG. 6 illustrates a schematic representation of a filling systemin accordance with a preferred embodiment of the present invention forintroducing into a container a suspension or solution of apharmaceutical substance in a propellant under pressure, with the systemincorporating the filling head of FIG. 1; and

[0038] FIGS. 7 to 13 illustrate enlarged part-sectional side views ofpart of the filling head of FIG. 1 in a series of respective positionsrepresenting successive sequential steps in a container fillingoperation.

[0039] FIGS. 1 to 5 illustrate a filling head 2 in accordance with apreferred embodiment of the present invention.

[0040] The filling head 2 comprises a main body 4 which includes adownwardly-extending part 5 that extends from a lower surface 6 thereof,a fill actuator 7 disposed to one lateral side of the main body 4 and anexhaust actuator 10 disposed to the opposite lateral side of the mainbody 4. The filling head 2 further comprises an actuating mandrel 14disposed to and above the main body 4 by which the filling head 2 ismoved vertically. The filling head 2 still further comprises a slidebody 16 for receiving a container to be filled which is mounted to thedownwardly-extending part 5 of the main body 4 so as to be verticallymovable relative thereto.

[0041] The main body 4 includes a vertically-oriented passageway 20which is located substantially centrally therein and includes first andsecond horizontally-opposed openings 21, 22 at the upper end 24 thereofand a third opening 25 at the lower end 26 thereof which is located inthe downwardly-extending part 5. The first and second openings 21, 22communicate respectively with the fill actuator 7 and the exhaustactuator 10.

[0042] The fill actuator 7 comprises a housing 28 and a filling valveassembly 29 which is movably disposed thereto. The filling valveassembly 29 comprises a filling valve stem 30 which is slideablydisposed within an annular chamber 31 in the main body 4 and includes avalve sealing end 32 which seals against a valve seat 33 that definesthe first opening 21 of the passageway 20 in the main body 4. Thechamber 31 includes an inlet conduit 34 and an outlet conduit 35 formedin the main body 4 on opposing lateral sides of the chamber 31. Thefilling valve assembly 29 further comprises a reciprocally movablefilling valve member 36 which is axially coupled to the filling valvestem 30 and is sealingly disposed within an annular chamber 37 definedin the housing 28. The filling valve member 36 includes a radiallyoutwardly-extending part 38 which sealingly divides the chamber 37 intofirst and second chamber parts 39, 40, the first chamber part 39 beingnear to the filling valve stem 30 and the second chamber part 40 beingremote from the filling valve stem 30. The housing 28 includes a conduit41 which communicates with the second chamber part 40 of the chamber 37and is for connection to a source of a pressurised fluid. The fillingvalve assembly 29 yet further comprises biasing means 42, in thisembodiment a compression spring, for biasing the filling valve member 36and hence the filling valve stem 30 into the chamber 31 in the main body4. The application/withdrawal of fluid pressure via the conduit 41introduces/withdraws fluid from the second chamber part 40 of thechamber 37, thereby causing sliding movement of the filling valve member36 in the chamber 37, and thereby sliding movement of the filling valvestem 30 in the chamber 31. In this way, the valve sealing end 32 of thefilling valve stem 30 can be moved into and out of engagement with thevalve seat 33 that communicates with the first opening 21 of thepassageway 20 in the main body 4. The chamber 31 is sealed at the endthereof remote from the valve seat 33 and at the junction of the fillingvalve member 36 and the filling valve stem 30 by a flexible annular seal43 that surrounds the filling valve stem 30.

[0043] The exhaust actuator 10 comprises a valve block 44 which isdisposed in a cavity 45 in the main body 4, a housing 46 which isconnected to the valve block 44 and an exhaust valve assembly 48 whichis movably disposed within the housing 46.

[0044] The housing 46 comprises an annular support sleeve 49 and theexhaust valve assembly 48 comprises an exhaust valve stem 50 whichincludes a valve sealing end 51 and is slideably disposed in the supportsleeve 49. The exhaust valve stem 50 is generally conical in shape, andincreases in diameter away from the valve sealing end 51. In thisembodiment the exhaust valve stem 50 includes a peripheral ridge 52which acts to reduce the retention of substance thereon. The exhaustvalve assembly 48 further comprises a reciprocally movable exhaust valvemember 54 which is axially coupled to the exhaust valve stem 50 and issealingly disposed within an annular chamber 56 in the support sleeve49. The exhaust valve member 54 includes a radially outwardly-extendingcentral part 58 which sealingly divides the chamber 56 into first andsecond chamber parts 60, 62, the first chamber part 60 being near to theexhaust valve stem 50 and the second chamber part 62 being remote fromthe exhaust valve stem 50. The support sleeve 49 includes first andsecond conduits 64, 66 for connection to a source of a pressurisedfluid, each conduit 64, 66 communicating with a respective one of thefirst and second chamber parts 60, 62 of the chamber 56. Application offluid pressure via one of the conduits 64, 66 introduces fluid into arespective one of the first and second chamber parts 60, 62 of thechamber 56, thereby causing sliding movement of the exhaust valve member54 in the chamber 56, and thereby sliding movement of the exhaust valvestem 50 in the support sleeve 49. In this way, the valve sealing end 51of the exhaust valve stem 50 can be moved into and out of engagementwith an exhaust valve seat 67 provided by the valve block 44. Thehousing 46 further includes a generally annular chamber 70 in which thesupport sleeve 49 and the exhaust valve stem 50 are located, with thepart of the chamber 70 surrounding the generally conical exhaust valvestem 50 also being generally conical. The housing 46 yet furthercomprises an exhaust tube 71 which is disposed to a side thereof remotefrom the valve block 44 and communicates with the chamber 70.

[0045] The valve block 44 includes a conical recess 72 which is anextension of the chamber 70 in the housing 46 and at the bottom of whichis the exhaust valve seat 67. The valve block 44 further includes afluid passageway 73 therein which includes a first, inlet opening 74which communicates with the second opening 22 of the passageway 20 inthe main body 4 and a second, outlet opening 75 at the exhaust valveseat 67.

[0046] In order to provide the required mounting for the support sleeve49, the chamber 70 in the housing 46 is divided into three arcuatechamber parts 78, 80, 82 in the vicinity of the mounting of the exhaustvalve assembly 48 (as illustrated in FIG. 5). In this embodiment thethree arcuate chamber parts 78, 80, 82 are substantially equal incircular length.

[0047] The chamber 70 is configured principally to be exhausted with anexhaust gas passing from the valve block 44. In this embodiment thevalve block 44 includes a plurality of first exhaust gas inlet passages84 which surround the outlet opening 75 at the exhaust valve seat 67.The first exhaust gas inlet passages 84 include respective outlets 86which define an array, preferably a circular array, around the exhaustvalve seat 67, with the array being axially centred on a common axis ofthe exhaust valve stem 50, the exhaust valve seat 67 and the passageway73. At least those portions of the first exhaust gas inlet passages 84which define the outlets 86 are parallel to the passageway 73. In thisembodiment the outlets 86 are formed in the surface of the conicalrecess 72 in the valve block 44 and are located downstream, withreference to the direction of flow through the chamber 70, of the outletopening 75 of the passageway 73. The valve block 44 further includes anannular chamber 88 in an outer surface thereof which commonly connectsthe first exhaust gas inlet passages 84 and which is in communicationwith a conduit 90 in the main body 4 for supplying a source of anexhaust gas thereto. In this embodiment the conduit 90 is directedradially to the annular chamber 88, but in an alternative embodimentcould be directed tangentially.

[0048] The chamber 70 is further configured to be exhausted with anexhaust gas passing through the housing 46. In this embodiment thehousing 46 includes a plurality of second and third exhaust gas inletpassages 92, 93 downstream of the first exhaust gas inlet passages 84.The second and third exhaust gas inlet passages 92, 93 includerespective outlets 94, 95 which define an array, preferably a circulararray, around the exhaust valve seat 67 and communicate with the chamber70. At least those portions of the second and third exhaust gas inletpassages 92, 93 which include the outlets 94, 95 are parallel to thefirst exhaust gas inlet passages 84, and thus also parallel to thepassageway 73 in the valve block 44. The housing 46 includes an annularchamber 96 which commonly connects the second and third exhaust gasinlet passages 92, 93 and a conduit 98 in communication with the chamber96 for supplying a source of an exhaust gas thereto.

[0049] The slide body 16 is mounted for vertical sliding movementrelative to the main body 4 by first and second spaced biasing elements100, in this embodiment compression springs, disposed therebetween. Eachof the biasing elements 100 is mounted on a respective threaded member102, both of which threaded members 102 connect the slide body 16 to themain body 4. In the normal or inoperative configuration, the slide body16 is biased by the biasing elements 100 downwardly away from the mainbody 4 so as to be separated therefrom by a gap 103.

[0050] The slide body 16 includes a bore 104 for slideably receiving inmating relationship the downwardly-extending part 5 of the main body 4.The slide body 16 further includes a projection 105 on the upper surface106 thereof which is complementary to a corresponding recess 107 formedin the lower surface 6 of the main body 4 around thedownwardly-extending part 5. The bore 104 includes an annular seal 109which surrounds the downwardly-extending part 5 so as to form a fluidtight seal therebetween. The lower, distal end 110 of thedownwardly-extending part 5 is provided thereunder with an annular valvestem seal 112 which includes a central opening 113 which is aligned withthe passageway 20 in the main body 4, the inner and outer diameters ofthe valve stem seal 112 substantially corresponding respectively to theinner diameter of the third opening 25 in the passageway 20 and theinner diameter of the bore 104. The bore 104 defines a chamber 116 whichis configured to have an inner diameter that is larger than the outerdiameter of the valve stem of the container to be filled. The chamber116 includes a main, upper section 122 and lower section 123 which is ofslightly smaller diameter than the upper section 122 and defines anopening 124 through which the valve stem of the container to be filledextends. The slide body 16 yet further includes a conduit 126 which isin communication with the chamber 116. The slide body 16 furthercomprises an annular head seal 131 which is located below and surroundsthe opening 124 to the chamber 116. The head seal 131 is retained in acentral opening 133 in a seal retaining block 132 which provides thelower part of the slide body 16. The seal retaining block 132 includes adownwardly-extending recess 134 in a lower surface 135 thereof forreceiving the head of a container to be filled.

[0051] As illustrated in FIG. 7, in this embodiment a container 138 tobe filled by the filling head 2 comprises a body 139 which defines astorage chamber 140 for holding a suspension or solution of apharmaceutical substance in a propellant under pressure. The body 139includes a head 141 which includes a peripheral housing 142 that definesa metering chamber 143 and a valve stem 144 that is movably disposed inthe housing 142 and extends from the head 141. The valve stem 144 ismovable between an extended position (as illustrated in FIG. 7) and adepressed position (as illustrated in FIG. 8), the valve stem 144normally being biased by a compression spring 145 into the extendedposition. The valve stem 144 includes an L-shaped conduit 146 whichextends between a first, outlet opening 147 located at the distal end ofthe valve stem 144 and a second, inlet opening 148 located in thelateral wall of the valve stem 144. The valve stem 144 further includesa U-shaped conduit 151 in that part thereof which is always disposedwithin the container 138. The U-shaped conduit 151 includes first andsecond axially-spaced openings 153, 155 located in the lateral wall ofthe valve stem 144 and enables communication between the meteringchamber 143 and the storage chamber 140 of the container 138 via bores156 in the housing 142.

[0052] When the valve stem 144 is in the extended position (asillustrated in FIG. 7), the inlet opening 148 of the L-shaped conduit146 is located outside the body 139 of the container 138, and inparticular remote from the metering chamber 143 within the container138. Thus, when the valve stem 144 is in the extended position, thecontainer 138 is closed since there is no communication path between thestorage chamber 140 and the L-shaped conduit 146 in the valve stem 144.In the extended position, the U-shaped conduit 151 communicates via thefirst opening 153 and the bores 156 in the housing 142 with the storagechamber 140 and via the second opening 155 with the metering chamber143. In this position, with the container 138 inverted, the meteringchamber 143 is filled.

[0053] When the valve stem 144 is in the depressed position (asillustrated in FIG. 8), that is, one of either a fill position or adischarge position, the valve stem 144 is pushed down against thebiasing action of the biasing element 145, thereby to move the inletopening 148 of the L-shaped conduit 146 into communication with themetering chamber 143 and the U-shaped conduit 151 out of communicationwith the metering chamber 143 and solely in communication with thestorage chamber 140 via the bores 156 in the housing 142. In a fillingoperation, a solution or suspension of a pharmaceutical substance in apropellant under pressure is forced downwardly through the L-shapedconduit 146, through the metering chamber 143 and into the storagechamber 140 of the container 138 by being forced past an annular seal166 which surrounds the valve stem 144 at the bottom of the meteringchamber 143. During the discharge of a metered volume of a suspension orsolution of a pharmaceutical substance in propellant under pressure fromthe container 138, the metered volume of suspension or solution presentin the metering chamber 143 is permitted to flow outwardly through theL-shaped conduit 146 by the provision of a communication path betweenthe metering chamber 143 and the inlet opening 148 of the L-shapedconduit 146. In the discharge operation, the seal 166 prevents anyfurther of the suspension or solution in the storage chamber 140 fromentering the metering chamber 143 so that a precise volume isdischarged.

[0054] In this embodiment the principal structural components of thefilling head 2 are typically composed of stainless steel and the sealsare typically composed of nitrile rubber. The only exceptions are thediaphragm seals and the seals which come into contact with propellantwhich typically are composed of PTFE and the valve block 44 and theexhaust valve stem 50 which are typically composed of hardened stainlesssteel.

[0055]FIG. 6 illustrates a filling system which incorporates theabove-described filling head 2 for filling a container 138 with ametered volume of a suspension or solution of a pharmaceutical substancein a propellant under pressure.

[0056] The filling head 2 is included in a circulatory line, designatedgenerally by reference sign 170, in which a propellant under pressurecontaining a pharmaceutical substance in a suspension or solution iscirculated. The circulatory line 170 includes a mixing vessel 172 whichholds propellant containing pharmaceutical substance in a suspension orsolution. The mixing vessel 172 is pressurised, as is the remainder ofthe circulatory line 170, so that the propellant is not only underpressure, but is also maintained as a liquid where the boiling point ofthe propellant is lower than the ambient temperature. A line 176connects an outlet 174 of the mixing vessel 172 to a pump 178, whichpump 178 is provided to pump propellant around the circulatory line 170.Another line 180 connects the pump 178 to the inlet side of an inletvalve 182. A further line 183 connects the outlet side of the inletvalve 182 to a metering chamber 184. The metering chamber 184 isconfigured to receive a metered volume of the propellant containingpharmaceutical substance in a suspension or solution on opening of theinlet valve 182. The metered volume corresponds to the volume which isrequired to be introduced into the container 138 by the filling head 2.A yet further line 186 connects the metering chamber 184 to the fillinghead 2, specifically the inlet conduit 34 in the main body 4 of thefilling head 2. As described hereinabove, the inlet conduit 34communicates with the chamber 31 surrounding the filling valve stem 30and thence with the outlet conduit 35. A still further line 188 connectsthe filling head 2, specifically the outlet conduit 35 in the main body4 of the filling head 2, to the inlet side of an outlet valve 190. Astill yet further line 192 connects the outlet side of the outlet valve190 to an inlet 194 of the mixing vessel 172, thereby completing thecirculatory line 170. The filling system further includes a bypass valve196 which is provided in a line 198 connected between the inlet side ofthe inlet valve 182 and the outlet side of the outlet valve 190.

[0057] The operation of the filling head 2 in filling a container 138with a metered volume of a suspension or solution of a pharmaceuticalsubstance in a propellant under pressure and subsequently exhaustingresidual propellant under pressure containing pharmaceutical substancewill now be described hereinbelow with reference to FIGS. 6 to 13.

[0058] In a first step, as illustrated in FIG. 7, the head 141 of acontainer 138 to be filled is located within the downwardly-extendingrecess 134 in the seal retaining block 132 of the slide body 16. In thisposition, the head 141 of the container 138 bears against the head seal131 and the distal end of the valve stem 144 of the container 138 bearsagainst the valve stem seal 112, with the valve stem 144 being urgedinto the extended position by the biasing element 145. In this way, thechamber 116 is sealed by the valve stem and head seals 112, 131.Although not illustrated, it will be understood that the bottom of thecontainer 138 is supported and urged upwardly. Further, in thisposition, the biasing elements 100 urge the slide body 16 away from themain body 4 so as to provide the gap 103 therebetween, and both thefilling valve assembly 29 and the exhaust valve assembly 48 are closed.

[0059] In a second step, as illustrated in FIG. 8, the actuating mandrel14 is operated upon to move the main body 4 and both the fill actuator 7and the exhaust actuator 10 disposed thereto downwardly relative to theslide body 16 against the bias of the biasing elements 100. Thismovement causes the projection 105 to pass into the recess 107 and thegap 103 to be closed. Additionally, the downwardly-extending part 5 ofthe main body 4 is urged via the valve stem seal 112 against the distalend of the valve stem 144 of the container 138, thereby to push thevalve stem 144 downwardly to the depressed open position in which theinlet opening 148 of the L-shaped conduit 146 in the valve stem 144 isin communication with the metering chamber 143 of the container 138 andthe U-shaped conduit 151 in the valve stem 144 is located solely incommunication with the storage chamber 140 of the container 138 and outof communication with the metering chamber 143.

[0060] In a third step, as illustrated in FIG. 9, the filling valveassembly 29 is opened by retracting the valve sealing end 32 of thefilling valve stem 30 from the valve seat 33. A metered volume ofpropellant containing pharmaceutical substance in suspension or solutionpresent in the metering chamber 184 is then introduced through the inletconduit 34, through the annular chamber 31, through the passageway 20,through the L-shaped conduit 146 in the valve stem 144, through themetering chamber 143 of the container 138 and finally past the seal 166into the storage chamber 140 of the container 138 via the bores 156 inthe housing 142.

[0061] Prior to opening of the filling valve assembly 29, the inletvalve 182 and the outlet valve 190 in the circulatory line 170 areclosed. When the inlet valve 182 and the outlet valve 190 are closed,the line 183 connecting the inlet valve 182 to the metering chamber 184,the metering chamber 184, the line 186 connecting the metering chamber184 to the filling head 2 and the line 188 connecting the filling head 2to the inlet side of the outlet valve 190 are full of propellantcontaining pharmaceutical substance in suspension or solution. When themetering chamber 184 is emptied a volume of propellant under pressurecontaining pharmaceutical substance corresponding to that metered by themetering chamber 184 is passed through the line 186 and into the fillinghead 2 through the inlet conduit 34. In this way, a precisely meteredvolume of propellant containing pharmaceutical substance in suspensionor solution is introduced into the container 138. In order that the pump178 can continue to operate continuously, thereby continuing tocirculate the propellant containing pharmaceutical substance around thecirculatory line 170, when the inlet valve 182 and the outlet valve 190are closed, the bypass valve 196 is open.

[0062] In a fourth step, as illustrated in FIG. 10, after a meteredvolume of propellant containing pharmaceutical substance in suspensionor solution has been introduced into the container 138, the fillingvalve assembly 29 is closed by biasing the valve sealing end 32 of thefilling valve stem 30 against the valve seat 33. Thereafter, twoseparate operations are commenced in order to obviate the inadvertentrelease of propellant containing pharmaceutical substance into theatmosphere at the end of the filling operation.

[0063] In a first operation a pressurized fluid is supplied to theconduit 126 in the slide body 16. This fluid provides a sealing jacketin the chamber 116 and the space 167 defined between the innercircumference of the head seal 131 and the lateral wall of the valvestem 144 of the container 138. This fluid is supplied at a pressurehigher than the vapour pressure of the propellant under pressurecontaining pharmaceutical substance which remains in the passageway 20in the main body 4 and the valve stem 144 of the container 138. In apreferred embodiment the fluid is a gas. Preferably, the gas is one ofair or nitrogen.

[0064] In a second operation an exhaust gas, preferably one of air ornitrogen, is introduced under pressure into the chamber 70 in theexhaust actuator 10 via the first, second and third exhaust gas inletpassages 84, 92, 93. The exhaust gas is preferably heated to atemperature of at least about 35° C., more preferably from 35 to 50° C.,in order to prevent any of the propellant containing pharmaceuticalsubstance which is exhausted through the chamber 70 from re-liquefyingtherein. Typically, where air is used as the exhaust gas, the mass flowrate is in the range of from 0.1 to 10 grams/second, preferably around 2grams/second.

[0065] In a fifth step, as illustrated in FIG. 11, the actuating mandrel14 is partially raised thereby partially releasing the valve stem 144 ofthe container 138 to an intermediate position between the extendedclosed position (as illustrated in FIG. 7) and the depressed openposition (as illustrated in FIG. 8). In this intermediate position, theinlet opening 148 of the L-shaped conduit 146 in the valve stem 144 ofthe container 138 is raised so as not to be in communication with themetering chamber 143 of the container 138 but with the space 167 definedbetween the inner circumferential surface of the head seal 131 and thelateral wall of the valve stem 144 of the container 138 and the chamber116 in communication therewith. The propellant under pressure containingpharmaceutical substance which is present in the L-shaped conduit 146 inthe valve stem 144 and the passageway 20 in the main body 4 is preventedfrom escaping therefrom via the inlet opening 148 in the valve stem 144as a result of the overpressure of the fluid supplied via the conduit126. Thus, following the filling operation, and while the valve stem 144of the container 138 is still in communication with the filling head 2,the provision of a sealing jacket of a pressurised fluid around the partof the valve stem 144 which includes the L-shaped conduit 146 preventsthe propellant under pressure containing pharmaceutical substance whichremain in the L-shaped conduit 146 in the valve stem 144 and thepassageway 20 in the main body 4 from escaping through the inlet opening148 in the valve stem 144, which propellant containing pharmaceuticalsubstance would otherwise be subsequently released to the atmospherefollowing the removal of the container 138 from the filling head 2.

[0066] When the valve stem 144 is in this intermediate position, themetering chamber 143 of the container 138 is closed to the atmospheresince the L-shaped conduit 146 in the valve stem 144 does notcommunicate with the metering chamber 143 but rather only to the outsideof the container 138, and in particular with the space 167 definedbetween the inner circumferential surface of the head seal 131 and thelateral wall of the valve stem 144 and the chamber 116 in communicationtherewith. By providing the valve stem 144 in this intermediateposition, propellant under pressure containing pharmaceutical substancepresent in the metering chamber 143 cannot escape therefrom andtherefore only the propellant containing pharmaceutical substancepresent in the L-shaped conduit 146 in the valve stem 144 and thepassageway 20 in the main body 4 need be exhausted. The provision of asealing jacket of overpressure fluid about the part of the valve stem144 which includes the inlet opening 148 following the filling operationand during the exhaust operation further advantageously provides thatwhen the container 138 is ultimately removed from the filling head 2 (inthe final step following the step as illustrated in FIG. 13), noresidual propellant containing pharmaceutical substance can escape fromthe L-shaped conduit 146 in the valve stem 144 or the passage way 20 inthe main body 4 prior to exhaustion thereof through the exhaust actuator10.

[0067] In a sixth step, as illustrated in FIG. 12, the exhaust valveassembly 48 is opened by retraction of the valve sealing end 51 of theexhaust valve stem 50 from the exhaust valve seat 67. In this way, acommunication path is provided between the L-shaped conduit 146 in thevalve stem 144, the passageway 20 in the main body 4 and the chamber 70in the exhaust actuator 10. The release of pressure from the propellantcontaining pharmaceutical substance on opening of the exhaust valveassembly 48 causes the propellant to boil off as a gas and escapethrough the passageway 73 in the valve block 44 into the chamber 70. Inthis way, both the propellant and the pharmaceutical substance containedtherein escape from the L-shaped conduit 146 in the valve stem 144 andthe passageway 20 in the main body 4 into the chamber 70. The provisionof exhaust gas flows through the first, second and third exhaust gasinlet passages 84, 92, 93 create parallel flows to the gas escaping fromthe passageway 73 in the valve block 44. This configuration createssubstantially aligned flows between on the one hand the now gaseouspropellant entraining pharmaceutical substance escaping from thepassageway 73 in the valve block 44 and on the other hand the exhaustgas flows through the first, second and third exhaust gas inlet passages84, 92, 93 downstream thereof. This configuration provides a uniformflow of gas in the chamber 70 which entrains the propellant and thepharmaceutical substance that escapes from the passageway 20 in the mainbody 4 and the L-shaped conduit 146 in the valve stem 144. Preferably,the mass flow rate of the exhaust gas is at least 10 times the peak massflow rate of the gaseous propellant flowing into the chamber 70 when thepropellant boils off. In a preferred embodiment a vacuum pumpincorporating a filter is connected to the exhaust tube 71 so as tocollect the escaping pharmaceutical substance.

[0068] In a seventh step, as illustrated in FIG. 13, the exhaust valveassembly 48 is closed by urging the valve sealing end 51 of the exhaustvalve stem 50 against the exhaust valve seat 67, the fluid supplied tothe conduit 126 in the slide body 16 to provide a sealing jacket aroundthe part of the valve stem 144 which includes the inlet opening 148 isterminated and the exhaust gas supplied to the first, second and thirdexhaust gas inlet passages 84, 92, 93 is terminated. The actuatormandrel 14 is raised, thereby to raise again the filling head 2 relativeto the container 138 so that the slide body 16 is spaced by the normalgap from the main body 4. In this way, the valve stem 144 is raised fromthe intermediate position to the extended position, thereby to providethe metering chamber 143 of the container 138 in communication via theU-shaped conduit 151 in the valve stem 144 with the storage chamber 140of the container 138.

[0069] In a final step the container 138 is removed from the fillinghead 2 without inadvertent leakage of propellant and pharmaceuticalsubstance to the atmosphere. The filling head 2 is then ready for thenext filling cycle for a subsequent container.

[0070] Finally, it will be understood by a person skilled in the artthat the present invention has been described in its preferredembodiment and can be modified in many different ways without departingfrom the scope of the invention as defined in the appended claims.

1. A filling apparatus for introducing into a container a suspension orsolution of a substance, in particular a pharmaceutical substance, in apropellant under pressure, comprising: a main body (4) including apassageway (20) having an inlet opening (21) and first and second outletopenings (25, 22), the first outlet opening (25) communicating, in use,with a valve stem (144) extending from a head (141) of a body (139) of acontainer (138); a fill actuator (7) in communication with the inletopening (21) of the passageway (20) comprising a filling valve assembly(29) for selectively introducing propellant under pressure containing asubstance in a suspension or solution into the passageway (20); anexhaust actuator (10) in communication with the second outlet opening(22) of the passageway (20) comprising an exhaust valve assembly (48)for selectively exhausting propellant under pressure containingsubstance from the passageway (20) and including at least one exhaustgas conduit (84, 92, 93) having an outlet opening (86, 94, 95)configured so as, in use, to provide a flow of exhaust gas substantiallyaligned with a flow of propellant containing substance from the secondoutlet opening (22) of the passageway (20); and a container-engagingbody (16) for receiving, in use, the head (141) of the body (139) of thecontainer (138) which includes the valve stem (144).
 2. The fillingapparatus according to claim 1 , wherein the exhaust actuator (10)includes a plurality of first exhaust gas conduits (84), the respectiveoutlet openings (86) of which define an array surrounding the secondoutlet opening (22) of the passageway (20).
 3. The filling apparatusaccording to claim 2 , wherein the outlet openings (86) of the firstexhaust gas conduits (84) are disposed downstream, with respect to thedirection of flow, of the second outlet opening (22) of the passageway(20).
 4. The filling apparatus according to claim 2 or 3 , wherein thearray of outlet openings (86) of the first exhaust gas conduits (84)define a circular array.
 5. The filling apparatus according to any ofclaims 2 to 4 , wherein the exhaust actuator (10) includes a firstchamber (88) with which the first exhaust gas conduits (84) commonlycommunicate and a conduit (90) in communication with the first chamber(88) through which exhaust gas is delivered.
 6. The filling apparatusaccording to any of claims 2 to 5 , wherein the exhaust actuator (10)includes a plurality of second exhaust gas conduits (92), the respectiveoutlet openings (94) of which are downstream, with respect to thedirection of flow, of the outlet openings (86) of the first exhaust gasconduits (84) and define an array surrounding the second outlet opening(22) of the passageway (20).
 7. The filling apparatus according to claim6 , wherein the array of outlet openings (94) of the second exhaust gasconduits (92) define a circular array.
 8. The filling apparatusaccording to claim 6 or 7 , wherein the exhaust actuator (10) includes asecond chamber (96) with which the second exhaust gas conduits (92)commonly communicate and a conduit (98) in communication with the secondchamber (96) through which exhaust gas is delivered.
 9. The fillingapparatus according to any of claims 1 to 8 , wherein the exhaust valveassembly (48) includes an exhaust valve body (50) which is configuredselectively to be seated on or unseated from a valve seat (67) disposedat the second outlet opening (22) of the passageway (20) and asubstantially annular chamber (70) which surrounds the exhaust valvebody (50) through which, in use, flows propellant containing substanceand exhaust gas when the exhaust valve body (50) is unseated from thevalve seat (67).
 10. The filling apparatus according to claim 9 ,wherein the annular chamber (70) is conical in shape, increasing indiameter from the second outlet opening (22) of the passageway (20). 11.A filling system for introducing into a container a suspension orsolution of a substance, in particular a pharmaceutical substance, in apropellant under pressure incorporating the filling apparatus accordingto any of claims 1 to 10 .
 12. A method of introducing into a containera suspension or solution of a substance, in particular a pharmaceuticalsubstance, in a propellant under pressure, comprising the steps of:providing a container (138) comprising a body (139) defining a storagechamber (140) and a valve stem (144) extending from the body (139);communicating the valve stem (144) of the container (138) with a firstoutlet opening (25) of a passageway (20) in a main body (4) of a fillingapparatus (2), the filling apparatus (2) comprising a fill actuator (7)comprising a filling valve assembly (29) for selectively introducinginto an inlet opening (21) of the passageway (20) propellant underpressure containing a substance in a suspension or solution and anexhaust actuator (10) comprising an exhaust valve assembly (48) forselectively exhausting propellant under pressure containing substancefrom a second outlet opening (22) of the passageway (20) and includingat least one exhaust gas conduit (84, 92, 93) having an outlet opening(86, 94, 95) configured so as, in use, to provide a flow of exhaust gassubstantially aligned with a flow of propellant containing substancefrom the second outlet opening (22) of the passageway (20); opening thefilling valve assembly (29) thereby to fill the storage chamber (140) ofthe container (138) with propellant under pressure containing asubstance in a suspension or solution; closing the filling valveassembly (29); providing exhaust gas through the at least one exhaustgas conduit (84, 92, 93); and opening the exhaust valve assembly (48) toenable propellant under pressure containing substance in the passageway(20) and the valve stem (144) of the container (138) to exhaust, wherebythe exhausted propellant containing substance is entrained in theexhaust gas.
 13. The method according to claim 12 , wherein the exhaustactuator (10) includes a plurality of first exhaust gas conduits (84),the respective outlet openings (86) of which define an array surroundingthe second outlet opening (22) of the passageway (20).
 14. The methodaccording to claim 13 , wherein the outlet openings (86) of the firstexhaust gas conduits (84) are disposed downstream, with respect to thedirection of flow, of the second outlet opening (22) of the passageway(20).
 15. The method according to claim 13 or 14 , wherein the array ofoutlet openings (86) of the first exhaust gas conduits (84) define acircular array.
 16. The method according to any of claims 13 to 15 ,wherein the exhaust actuator (10) includes a first chamber (88) withwhich the first exhaust gas conduits (84) commonly communicate and aconduit (90) in communication with the first chamber (88) through whichexhaust as is delivered.
 17. The method according to any of claims 13 to16 , wherein the exhaust actuator (10) includes a plurality of secondexhaust gas conduits (92), the respective outlet openings (94) of whichare downstream, with respect to the direction of flow, of the outletopenings (86) of the first exhaust gas conduits (84) and define an arraysurrounding the second outlet opening, (22) of the passageway (20). 18.The method according to claim 17 , wherein the array of outlet openings(94) of the second exhaust as conduits (92) define a circular array. 19.The method according to claim 17 or 18 , wherein the exhaust actuator(10) includes a second chamber (96) with which the second exhaust gasconduits (92) commonly communicate and a conduit (98) in communicationwith the second chamber (96) through which exhaust gas is delivered. 20.The method according to any of claims 12 to 19 , wherein the exhaustvalve assembly (29) includes an exhaust valve body (50) which isconfigured selectively to be seated on or unseated from a valve seat(67) disposed at the second outlet opening (22) of the passageway (20)and a substantially annular chamber (70) which surrounds the exhaustvalve body (50) through which, in use, flows propellant containingsubstance and exhaust gas when the exhaust valve body (50) is unseatedfrom the valve seat (67).
 21. The method according to claim 20 , whereinthe annular chamber (70) is conical in shape, increasing in diameterfrom the second outlet opening (22) of the passageway (20).
 22. Themethod according to any of claims 12 to 21 , wherein the exhaust gas isheated to a temperature of at least about 35° C.
 23. The methodaccording to any of claims 12 to 22 , wherein the ratio of the mass flowrate of the exhaust gas to the exhausted propellant containing substanceis at least 10:1.
 24. The method according to any of claims 12 to 23 ,wherein the exhaust gas has a mass flow rate of from 0.1 to 10grams/second.
 25. The method according to any of claims 12 to 24 ,wherein the exhaust gas comprises pressurised air.